Filter frame attachment and fluted filter having same

ABSTRACT

A filter element includes a filter media pack, a frame, an annular seal, and a sealing means independent of the annular seal, attaching the filter media pack and the frame. The means of sealing an interface between the filter media pack and the frame include molding a filter media pack seal, plastic welding outer wraps of filter media pack to the frame, and securing the filter media pack and the frame using a bead of adhesive.

FIELD OF THE INVENTION

This invention generally relates to fluid filters, and more particularlyto fluted filter elements having frames and seal support structures, andattachment methods for the same.

BACKGROUND OF THE INVENTION

Filtration devices and systems are employed in a wide range ofapplications for filtering contaminants from various process fluids. Forexample, it is known to pass air or similar gases through filterassemblies that enclose filtration media such as filter paper to removedust and other contaminants. The filtration media is typically enclosedwithin a housing that is a permanent part of a larger overall processsystem (e.g. an engine) that utilizes the filtered fluids. Desirably, toprevent clogging of the filter, the filter assembly is constructed tofacilitate the removal and replacement of the filtration media from thepermanent housing. For this reason, the filtration media is typicallyconfigured into removable filter elements, also referred to herein asfilter cartridges.

One commonly used filter media in construction of filter elements isfluted filter media. Fluted filter media is typically formed by windinga convoluted sheet and a face sheet about an axis to form a plurality ofcontiguous adjacent flutes. In one common form of such fluted filtermedia, alternating ends of adjacent flutes are blocked to cause fluidentering one open end of “inlet” flutes to flow through the porousfilter media into adjacent “outlet” flutes prior to exiting the filtermedia at an opposite end of the flutes.

To enable removal of a filter element from the filter housing (notshown), typically a clearance gap is provided between the twocomponents. To cause process fluids to pass through the filtration mediarather than short circuit around the filter element, the filter elementis often provided with a seal that abuts against the filter housing.Prior such filter elements are disclosed in U.S. Pat. No. 6,610,117(Gieseke), U.S. Patent Application Publication No. 2006/0091061 (Brown),and U.S. Patent Application Publication No. 2006/0090434 (Brown, et al.)herein incorporated by reference in their entireties.

The present invention pertains to improvements in frames, seal supportstructures and how they are attached to a filter, such as a flutedfilter.

BRIEF SUMMARY OF THE INVENTION

One inventive aspect pertains to separately molding seal support frameto filter pack apart from an annular seal carried by the frame.According to this aspect, the invention provides a filter elementincluding a filter media pack with two flow faces on opposite ends witha central axis passing through the flow faces, and a frame secured tothe filter media pack. The frame has a seal support portion carrying aseal for engaging a filter housing and forms at least a portion of amolding receptacle region. An interface between the filter media packand the frame is sealed by a filter media pack seal generally occupyingthe molding receptacle region. The filter media pack of the presentinvention may be a fluted filter media including a face sheet and aconvoluted sheet secured together and wound about the central axis todefine a plurality of flutes including first flutes closed proximate oneface and second flutes closed proximate the other face. The filter mediapack of the present invention also may be other suitable filter mediafor filtering contaminants from fluid streams.

In another aspect, the invention provides a filter element wherein afluted filter media pack is secured to a frame by plastic welding. Theframe in this embodiment is formed at least in part from plasticmaterial such that the outer wrap or wraps or outer side of the filtermedia pack is welded to the plastic portion of the frame using asuitable plastic welding process.

The present invention also provides for various methods of making afilter element. In one aspect, the invention provides a method of makinga filter element including steps of forming a filter media pack havingouter wraps, manufacturing a frame having a seal support portion andforming at least a portion of a molding receptacle region, molding anannular seal around the seal support portion, and separately molding afilter media pack seal generally occupying the molding receptacleregion, thereby sealing an annular interface between the filter mediapack and the frame.

In another aspect, the invention provides a method of securing a filtermedia pack to a frame including steps of forming a fluted filter mediapack with outer wraps, manufacturing a frame with an annular plasticportion adapted for welding the outer wraps of the filter media pack,and welding the outer wraps of the filter media pack to the annularplastic portion.

According to a further aspect of the invention, a method of making afluted filter element includes forming a frame including a seat and anannular wall surrounding the seat, laying an adhesive bead around theannular wall in spaced relation from the seat, and inserting the filtermedia pack into the annular wall toward the seat and engaging theadhesive bead causing the adhesive bead to shear along the annular wallin a continuous ring toward the seat.

Other aspects, objectives and advantages of the invention will becomemore apparent from the following detailed description when taken inconjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings incorporated in and forming a part of thespecification illustrate several aspects of the present invention and,together with the description, serve to explain the principles of theinvention. In the drawings:

FIG. 1 is a perspective view of a filter element including separateseals according to a first embodiment of the invention, adapted forinsertion into a filter housing;

FIG. 2 is a perspective partial cross-sectional view of the firstembodiment including a fluted filter media pack, a frame, a windingcore, a border frame, an annular seal, and a filter media pack sealindependent of the annular seal;

FIG. 3 is a fragmentary and cross-sectional view of the first embodimentdepicted in FIGS. 1 and 2, in a mold, showing an arrangement of thefilter media pack seal and the separately formed annular seal relativeto the filter media pack and the frame;

FIG. 4 is another perspective partial cross-sectional and fragmentaryview of a lower portion of the first embodiment (e.g. the top portion ofthe filter media pack is cut away) showing the filter media pack sealformed separately from the annular seal with a molding platform as abarrier between the seals;

FIG. 5 is the perspective partial cross-sectional and fragmentary viewof the first embodiment in FIG. 4 shown in the mold wherein the filtermedia pack seal and the annular seal are formed;

FIG. 6 is a fragmentary and cross-sectional view of a second embodimentof the invention showing an annular seal formed in a mold, and anannular sealing interface between the filter media pack and a frameformed by plastic welding outer wraps of the filter media pack to theframe;

FIG. 7 is a perspective partial cross-sectional and fragmentary view ofa lower portion of the second embodiment (e.g. the top portion of thefilter media pack is cut away) showing the sealing interface formedbetween the filter media pack and the frame without using a sealingmaterial, and an annular seal carried by the seal support portion of theframe;

FIG. 8 is the perspective partial cross-sectional and fragmentary viewof the second embodiment in FIG. 7 shown in the mold wherein the annularseal is formed;

FIG. 9 is a fragmentary and cross-sectional view of a third embodimentof the invention showing a filter media pack seal formed in a moldingreceptacle portion of the frame, and an annular seal separately formedin a mold;

FIG. 10 is a perspective partial cross-sectional and fragmentary view ofa lower portion of the third embodiment (e.g. the top portion of thefilter media pack is cut away) showing the filter media pack sealenclosed by the molding receptacle portion and the annular sealseparately carried by the seal support portion of the frame;

FIG. 11 is the perspective partial cross-sectional and fragmentary viewof the third embodiment in FIG. 10 shown in the mold wherein the annularseal is formed;

FIG. 12 is a fragmentary and cross-sectional view of a fourth embodimentof the invention showing a frame with an adhesive bead appliedcontinuously along an inner annular wall and an annular seal in a mold,carried by a seal support portion of the frame, before a filter mediapack is inserted into the frame;

FIG. 13 is the fragmentary and cross-sectional view of the fourthembodiment in FIG. 12 as the filter media pack engages the adhesive beadafter the filter media pack is inserted into the frame guided by achamfer of the frame;

FIG. 14 is the fragmentary and cross-sectional view of the fourthembodiment in FIG. 12, after the filter media pack has completelytraveled down the annular wall of the frame, showing an elongatedadhesive bead between a periphery of the filter media pack and the innerannular wall of the frame, thereby sealing the filter media pack withthe frame;

FIG. 15 is the perspective partial cross-sectional and fragmentary viewof the first embodiment in FIG. 5 shown with the filter element removedfrom the mold after the filter media pack seal and the annular seal areformed;

FIG. 16 is a fragmentary and cross-sectional view of a fifth embodimentin a mold having an undercut, showing an arrangement of a filter mediapack seal and a separately formed annular seal relative to a filtermedia pack and the frame;

FIG. 17 is a different fragmentary and cross-sectional view of the fifthembodiment of FIG. 16 in a mold having an undercut;

FIG. 18 is a perspective partial cross-sectional and fragmentary view ofa lower portion of the fifth embodiment (e.g. the top portion of thefilter media pack is cut away) showing the filter media pack seal formedseparately from the annular seal with a molding platform as a barrierbetween the seals;

FIG. 19 is the perspective partial cross sectional and fragmentary viewof the fifth embodiment in FIG. 17 shown in the mold with the undercutwherein the filter media pack seal and the annular seal are formed;

FIG. 20 is a perspective top view of an embodiment according to thepresent invention including a boarder frame integrally bonded to thefilter media pack;

FIG. 21 is a fragmentary and cross-sectional view of the embodiment ofFIG. 20 showing the frame formed in a mold and integrally bonded to thefilter media pack;

FIG. 22 is a different fragmentary and cross sectional view of theembodiment of FIG. 20 showing the frame including ribs formed in a moldand integrally bonded to the filter media pack; and

FIG. 23 is a fragmentary and cross-sectional view of a sixth embodimentin a mold having an undercut, showing an arrangement of a filter mediapack seal and a separately formed annular seal relative to a filtermedia pack and the frame; and

FIG. 24 is the perspective partial cross-sectional and fragmentary viewof the first embodiment in FIG. 23 shown with the filter element removedfrom the mold after the filter media pack seal and the annular seal areformed.

While the invention will be described in connection with certainpreferred embodiments, there is no intent to limit it to thoseembodiments. On the contrary, the intent is to cover all alternatives,modifications and equivalents as included within the spirit and scope ofthe invention as defined by the appended claims.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1 and 2 show a first embodiment of the present invention in theform of a filter element 10, adapted for insertion into a filter housingfor removing particulate matter from a flow of fluid passing through thefilter housing. The term fluid as used herein is intended to includefluids in either liquid or gaseous forms; however, the embodiments shownherein illustrate an air filter of the type used for filtering intakeair for engine and air compressors. It is understood that inventivefeatures may also be applicable to liquid applications.

The filter element 10 of the first embodiment is generally shown inFIGS. 1 and 2 as an annular shape with a race-track-like cross section.The term “annular” is used herein in accordance with the commondictionary definition to describe a variety of ring-like shapes disposedabout an axis or centerline. Annular shapes, as contemplated by theinventors, may include, but are not limited to, shapes that are round,rectangular, oval, or race-track-like with two generally straight andparallel sides joined by rounded ends.

To generally introduce different components, the filter element 10, asshown in FIGS. 1 and 2, includes a filter media pack 12, a seal supportframe 14 having a flow face grid 15, a filter media pack seal 16, anannular seal 18, a border frame 19, and a winding core 28.

Referring to FIGS. 1-5, the filter media pack 12 of the first embodimentis shown as a fluted filter media with a central axis 24 passing throughopposed flow faces 20, 22. The fluted filter media pack 12 includes aface sheet 21 and a convoluted sheet 23 secured together and wound aboutthe winding core 28 to define a plurality of flutes. First set of theplurality flutes are closed proximate an inlet flow face 20 and secondset of the plurality of flutes are closed proximate an outlet flow face22, such that fluids entering the flutes, which are open at the inletflow face 20, flow through the porous filter media into other flutesprior to exiting the filter media at the outlet flow face 22 of theflutes. In alternative embodiments, the fluted filter media pack 12 maybe formed without using the winding core 28.

The outer edge of the inlet flow face 20 can be protected by the borderframe 19. The border frame 19 reduces risk of damages to the filterelement 10 during handling or installation by providing a rim around theperiphery of the filter media pack 12 at a corner thereof. As shown inFIGS. 1 and 2, the border frame 19 is a plastic ring member that can beglued or plastic welded to the filter media pack 12, or removably placedthereon. The border frame 19 may also be formed with any suitablematerials including, but not limited to, urethane materials, otherpolymers, metal and the like.

FIG. 20 illustrates an alternative embodiment of the border frame. Inthis embodiment a border frame 150 is integrally bonded to the filtermedia pack 12. As shown in FIG. 20, the border frame 150 has ribs 152,154. In addition to providing protection to the corner and outer edgesof the inlet flow face 20, the border frame 150 includes the ribs 152,154 that may also provide a structural support across the inlet flowface 20 and also prevent damage to inlet flow face. The border frame150, as illustrated in FIG. 20, is race-track-like shaped including twoparallel sides 156, 158. The ribs 152, 154 are integrally formed withthe border frame 150 and extend from one side of the border frame 156 tothe other side 158. The border frame 150 also includes a plurality oflocation reliefs 160 that extend inwardly to filter paper or protectivewrap with or without a thin flash of urethane material coating (i.e. themold is located against the outer periphery of filter media pack). Eachof the plurality of location reliefs 160 is indented from the sidesurface of the border frame 150 and matches a corresponding locating ribof a mold as discussed in detail below. The border frame 150 is shown inFIG. 20 with ten location reliefs 160, wherein the location reliefs aregenerally spaced equally from one another with about a 3 inches spacebetween them. However, other embodiments may include more or less numberof location reliefs 160, which may or may not be spaced equally fromeach other.

The border frame 150 may be integrally bonded to the filter medial pack12 via molding or plastic welding. Preferably, the border frame 150 ismolded in a mold designed according to a desired shape of the borderframe 150. FIGS. 21 and 22 show the border frame 150 molded to thefilter media pack 12 in a mold 180 in fragmentary cross-sectional views.The mold 180 includes an annular cavity 182 and rib cavities 184extending from one side of the annular cavity to the other side. Themold 180 also includes a plurality of locating ribs 186. As previouslydiscussed, the border frame 150 is shown with ten location reliefs, thusthe mold 180 for the border frame 150 will have ten correspondinglocating ribs 186. The locating ribs are protrusions extending from aninner wall 192 of the mold 180 above the annular cavity. The locatingribs may be configured to have a rounded end or flat surface end whichwill form corresponding location reliefs 160.

During the molding process, an uncured fluid frame material such as anuncured rigid urethane is poured into the mold cavities 182, 184, andthe filter media pack 12 is inserted. The filter media pack 12 is guidedby the plurality of locating ribs 186 into the mold 180. The filtermedia pack 12 is generally centered in the mold 180 with a gap 188between the periphery of the filter media pack 12 and each of theplurality of locating ribs 186. A size of the gap 188 between a locatingrib and the filter media pack periphery may slightly vary from onelocating rib to another. Occasionally, some locating ribs may push intothe adjacent periphery of the filter media pack 12 leaving indentations,while other locating ribs are spaced from the periphery of the filtermedia pack 12 with a larger gap 188 than if the filter media pack 12 wascentered in the mold 180. FIG. 21 illustrates the filter media pack 12in the mold 180, cut across one of the locating ribs 186 showing the gap188 between the locating rib 186 and the periphery of the filter mediapack 12.

FIG. 22 also shows the filter media pack 12 in the mold 180, but cutacross between locating ribs 186. As such, FIG. 22 shows a gap 190between the inner wall 192 of the mold 180 and the periphery of thefilter media pack 12. The size of the gap 190 is generally larger thanthe gap 188.

In the annular cavity 182, some of the uncured fluid frame materialenters openings formed by some flutes along the outer wraps of thefilter media pack 12. Similarly, some of the uncured fluid material inthe rib cavities 184 extends into opening of some adjacent flutes.Additionally, the uncured fluid frame material in the annular cavity 182extends up around the periphery of the filter media pack 12, partiallyentering the gap 188 and the gap 190. In the embodiments where thefilter media pack 12 is off centered with some locating ribs pushed intothe periphery of the filter media pack 12, the gap 188 at those locatingribs may be very minimal, yet the uncured fluid frame material stillseeps between the pushed in locating ribs and the periphery of thefilter media pack.

The uncured fluid frame material in the gap 188 and 190 cures to formthe periphery of the border frame 150. A thickness of portions of theborder frame 150 formed in the gap 190 is thicker than portions formedin the gap 188, since the gap 190 is larger than the gap 188. Theportions of the border frame 150 formed in the gap 188 define thelocation reliefs 160. (See FIG. 20). The thickness of the periphery ofthe border frame 150 may vary from one point to another. As such, someportions of the border frame 150 may be flush with the periphery of thefilter media pack 12, while other portions extend beyond the peripheryof the filter media pack 12. As the uncured fluid frame material in theopenings of some flutes, the gap 188 and the gap 190 cures, the borderframe 150 is formed, integrally bonding with the filter media pack 12.Preferably the border frame embeds in the filter media pack either intothe porosity of the filter paper, outer wrap thereof and/or by fillingthe flutes defined by the filter pack to provide secure attachment.

The border frame 150 can be formed of any suitable polymeric materials,preferably a rigid urethane which is advantageous in providingstructural support for the filter media pack 12. When the border frame150 is formed of a rigid urethane, it preferably does not perform asealing function between the filter element 10 and the filter housing.In other embodiments, the border frame 150 may be formed of a softermaterial such as a softer polyurethane foam. Although, the abovedescribed border frame 150 includes the plurality of location reliefs160 formed by the corresponding plurality of locating ribs 186, theborder frame 150 may be formed without the plurality of locating ribs186, thus no location reliefs may be found in those embodiments.

Alternatively, the border frame 150 may also be attached via plasticwelding. In such an embodiment, the border frame 150 is formed at leastin part of a suitable thermoplastic material, wherein one side of theborder frame 150 is heated until soft, then the filter media pack 12 iscentered on the border frame 150 and pressed against it such that someof the softened frame material oozes through openings of adjacentflutes. As such, the filter media pack 12 is partially embedded in theborder frame 150. The border frame 150 and the filter media pack 12 aresecured together as the softened frame material solidifies as it iscooled.

In the embodiment shown in FIG. 20, the securely attached border frame150 having the ribs 152, 154 protects and provides structural support tothe filter media pack 12 on the inlet flow face 20, while the supportframe 14 having a flow face grid 15 supports the outlet flow face 22.Such structural support on both flow faces 20, 22 holds and retains theshape of the filter media pack 12 by preventing telescoping and protectsthe flow faces 20, 22 from damages during handling and installation.Although, the border frame 150 of FIG. 20 only includes two ribs 152,154, other embodiments may include one or more than two ribs.

Now referring back to FIGS. 1-5, at the other end of the filter mediapack 12, a seal support frame 14 is provided for carrying the annularseal 18 for engaging the filter housing. The outlet flow face 22 and/orouter side of the filter media pack 12 is secured to the seal supportframe 14 by the filter media pack seal 16 that circumscribes and bondsthe filter media pack 12. The seal support frame 14 typically includesthe flow face grid 15 extending across the outlet flow face 22 of thefilter media pack 12. The flow face grid 15 is provided to resistpressure forces acting on the filter media pack 12, which could causethe center of the filter media pack 12 to telescopically bow outward ina downstream direction. Such flow face grid 15 extending across theoutlet flow face 22 may be particularly beneficial for fluted filtermedia packs formed by coiling layers of convoluted filter material, inorder to prevent the center of the filter media pack 12 from telescopingunder high inlet fluid pressures.

In addition to performing a securing function, the filter media packseal 16 seals an annular interface between the filter media pack 12 andthe seal support frame 14. The seal support frame 14 includes a spacer36 and a molding platform 38 defining a portion of a molding receptacleregion 34 as shown in FIGS. 3-5. The spacer 36 and the molding platform38 act as barriers containing the filter media pack seal 16 within themolding receptacle region 34. The spacer 36 also allows the sealmaterial of the filter media pack seal 16 to undercut and seal outerwrap or wraps of the filter media pack 12. The filter media pack seal 16further extends around an outer periphery of the filter media pack 12proximate the annular interface and seals the annular interface.

The seal support frame 14 further includes a seal support portion 26wherein the annular seal 18 is formed and supported. The primaryfunction of the annular seal 18 is to provide a sealing surface betweenthe filter element 10 and the filter housing to prevent unfilteredfluids from passing between the filter element 10 and the filterhousing. The filter housing often includes a generally tubular wallsection. In order to facilitate removal and replacement of the filterelement 10, the filter element 10 is provided with the annular seal 18which is compressible for inserting the filter element 10 into thefilter housing. When the filter element 10 is inserted into the filterhousing, the annular seal 18 seals an interface between an inner surfaceof the tubular wall section and the filter element 10, therebypreventing fluids from bypassing the filter element 10 while flowingthrough the filter housing.

The filter media pack seal 16 and the annular seal 18 may be molded fromany suitable sealing materials including but not limited to polymericmaterials and polymer foams, preferably, polyurethane foam. The seals16, 18 may be formed using the same material or may be formed from twodifferent materials. Moreover, the filter media pack seal 16 may providean additional sealing surface between the filter element 10 and thefilter housing while securing and sealing the interface between thefilter media pack 12 and the frame 14 at the same time.

The filter media pack seal 16 and the annular seal 18 are formed in amold 32 in the first embodiment. FIG. 3 shows a mold 32 in conjunctionwith the sealing frame region to illustrate how the filter media packseal 16 and the annular seal 18 can be formed separately. Referring toFIGS. 3 and 5, the mold 32 includes an annular cavity 42, a peripheralwall 44 which has an inner wall 46 and an outer wall 48, and locatingribs 51. The inner wall 46 includes a tapered region 50 adapted forabutting the molding platform 38 of the support frame 14, defining aportion of the molding receptacle region 80.

The molding platform 38 includes a flange portion 38 a with a terminalfree edge which has a chamfered seating surface 40 adapted to abut thetapered region 50. The chamfered seating surface 40 is designed toposition the seal support frame 14 as the frame 14 is inserted into themold 32, such that the seal support portion 26 is placed in an annularcavity 42 of the mold 32, and the chamfered seating surface 40 issupported against the tapered region 50 of the mold 32. When the frame14 is positioned as such that the chamfered seating surface 40 abuts thetapered region 50, the molding receptacle region 34 is defined by thespacer 36, the molding platform 38 and the inner wall 46 of the mold 32

A method of making the filter element 10 of the first embodiment, asillustrated in FIGS. 1-5, can include steps of forming the filter mediapack 12, molding the seal support frame 14 from plastic material toprovide the seal support portion 26 and a portion of the mold receptacleregion 34, molding of an annular seal 18 on the seal support portion 26,and separately molding a filter media pack seal to secure and seal thefilter media pack 12 to the seal support frame 14. The filter media pack12 may be constructed from a convoluted sheet of porous filter media 23secured together with a face sheet 21 of porous filter media. Theconvoluted sheet 23 may be formed by any appropriate process, such ascorrugating or pleating, but preferably by gathering as described inU.S. patent application Ser. No. 10/979,390, entitled “Gathered FilterMedia for an Air Filter and Method of Making Same,” assigned to theAssignee of the present invention, and incorporated herein by reference.

The term face sheet, as used herein, is intended to encompass any formof sheet or strip of generally flat, porous or non-porous, materialattached to the convoluted sheet of porous filter material. In mostembodiments of the invention, the face sheet would preferably be formedof a porous filter material.

The convoluted sheet of porous filter material 23 forms a plurality ofcontiguous adjacent convolutions, commonly known in the industry asflutes 54. Selected ends of the flutes may be blocked, with a bead ofadhesive 56, for example, to cause fluid entering one end of some of theflutes to flow through the porous filter media into other flutes priorto exiting the filter media at an opposite end of the flutes, in themanner known in the art.

The filter media pack 12 in FIGS. 1-5 is formed by winding and coilingthe filter media to form a generally annular shape, such as arace-track-like cross section, that is proportioned for insertion into afilter housing having a generally same inner surface shape with a largerperimeter than the filter element 10 to provide a sliding clearance fit.The filter media pack 12 may be constructed with the winding core 28 asdisclosed in U.S. patent application Ser. No. 11/634,647, entitled“Fluid Filter Apparatus Having Filter Media Wound About a WindingFrame,” assigned to the Assignee of the present invention, andincorporated herein by reference. In other embodiments of the invention,the filter media pack 12 having other cross-sectional shapes, such ascircular, square, rectangular, or polygonal, for example, may beutilized by coiling or bonding together successive wraps of the filtermedia. It is also understood that the invention is not limited to afilter media pack of fluted media. Those having skill in the art willreadily recognize that the invention may also be practiced withefficacy, using other types of filter media.

Still referring to FIGS. 1-5, the seal support frame 14 is preferablymolded of a suitable plastic material. The flow face grid 15 may beformed integrally with the seal support frame 14. The first embodimentin FIGS. 1-5 depicts the filter element 10 with the seal support frame14 integrally formed with the flow face grid 15 secured against theoutlet flow face 22. However, alternative embodiments may include theflow face grid 15 formed independently from the frame 14, or may includethe flow face grid 15 secured against both flow faces or the inlet flowface 20.

The embodiment shown in FIGS. 1-5 shows the annular seal support 26 as acanted annular extension projecting from the outlet flow face 22 at anoblique angle to the central axis 24. The canted extension may include aplurality of holes with the annular seal 18 including a portion thereofextending through the holes to help retain the annular seal 18 on theseal support portion 26 as disclosed in U.S. patent application Ser. No.10/979,876, entitled “Filter Element with Canted Seal Support,” assignedto the Assignee of the present invention, and incorporated herein byreference. The frame 14 includes the spacer 36 and the molding platform38 with the chamfered seating surface 40 defining a portion of themolding receptacle region 34 as described above.

The annular seal 18 can be molded around the seal support portion 26 ofthe seal support frame 14 in the mold 32 having the annular cavity 42.In a molding process, an uncured fluid sealing material for the annularseal is poured into the annular cavity 42. The frame 14 is then insertedinto the mold 32 with the seal support portion 26 facing downward asshown in FIGS. 3 and 5. When the seal support frame 14 is inserted intothe mold 32, the chamfered seating surface 40 of the molding platform 38slides down on the tapered region 50 of the mold inner wall 46,positioning the frame 14 such that the seal support portion 26 is in theannular cavity 42 and the chamfered surface 40 of the molding platform38 abuts the tapered region 50 along a continuous annular interface toprevent seepage of seal material thereby while in an uncured state.

In the annular cavity 42, the uncured fluid sealing material is allowedto foam and rise up around the seal support portion 26. The seal supportportion 26 also may include an annular rib 60 extending therefrom, asshown in FIG. 3, for contacting and sealing against the mold 32, therebylimiting the extent of the annular seal 18 along the support portion 26.The uncured fluid sealing material may include, but not limited to,various foaming polymers such as polyurethane. The uncured fluid sealingmaterial foams around the seal support portion in a shape of an innersurface of the annular cavity 42, forming the annular seal 18. It isdesirable that the uncured fluid sealing material cures into a sealingmaterial having an elasticity characteristic suitable for sliding thefilter element 10 in and out of the filter housing, and also providing asealing surface between the filter element 10 and the filter housing,thereby preventing unfiltered fluids from passing between the filterelement 10 and the filter housing.

When the seal support frame 14 is placed in the mold 32 for molding ofthe annular seal 18, as described above, the molding receptacle region34 is formed by the spacer 36, the molding platform 38 and the moldinner wall 46. The interface between the seal support frame 14 and themold inner wall 46 is closed when the chamfered seating surface 40 ofthe molding platform 38 abuts against the tapered region 50 of the moldinner wall 46. The molding receptacle region 34 is divided from theannular cavity 42 by the molding platform 38, thereby allowing thefilter media pack seal 16 to form separately from the annular seal 18.

During a molding process of the filter media pack seal 16, an uncuredfluid sealing material for the filter media pack seal 16 is poured intothe molding receptacle region 34, then the filter media pack 12 isinserted into the mold 32. A plurality of angularly spaced locating ribs51 of the mold 32 (FIGS. 3 and 15) guides the filter media pack 12 suchthat the filter media pack 12 is generally centered onto the frame 14with the outer most wrap or wraps of the filter media pack 12 in themolding receptacle region 34. The filter media pack 12 is positionedsuch that the filter media pack 12 is spaced from the mold inner wall 46with generally an even annular space 62 between the outer periphery ofthe filter media pack 12 and the inner wall 46 of the mold 32.

The plurality of the locating ribs 51 can eliminate a stacking toleranceeffect during the molding process. That is, when the filter media pack12 is inserted onto the seal support frame 14 without the plurality ofthe locating ribs, there are two process tolerances to control duringthe molding process: a tolerance between the periphery of the filtermedia pack 12 and the mold 32, and a tolerance between the filter mediapack 12 and the seal support frame 14. Thus, the position of the annularseal 18 relative to the filter media pack 12 is controlled through twotolerances, resulting in an increased process tolerance between theannular seal 18 and the filter media pack 12. The plurality of thelocating ribs 51 allows placement of the filter media pack 12 on theseal support frame 14 to be controlled under one tolerance, thetolerance between the locating ribs 51 and the periphery of the filtermedia pack 12, thus eliminating the stacking tolerance effect for a morecontrolled molding process.

In the molding receptacle region 34, the uncured fluid sealing materialis allowed to foam, extending into openings formed by some flutes alongthe outer wraps of the filter media pack 12, and rise up around anannular interface between the filter media pack 12 and the seal supportframe 14, and further circumscribing a portion of the outer periphery 13of the filter media pack 12 proximate the interface. Both of theseregions provide seals extending continuously around the filter mediapack 12. The spacer 36 acts as a barrier to limit the uncured sealingmaterial from extending radially inward beyond the outer wraps of thefilter media pack 12, and allows the sealing material to undercut andseal the outer wrap or wraps of the filter media pack 12.

As the uncured fluid sealing material foams and cures, the filter mediapack seal 16 is formed following the contours of the adjacent inner wall46 of the mold 32. In this embodiment, an outer periphery of the filtermedia pack seal 16 includes a tapered region extending into a largerperiphery as defined by the tapered region 50 and the larger diameterportion of the inner wall 46. Preferably, the minimum radial thicknessof the filter media pack seal 16 (e.g. minimum distance between theouter side of the filter media pack 12 and the inner wall 46 of the mold32, not including any locating ribs, if any) is typically betweenminimum 0.03 inches and 0.2 inches to allow sufficient room for asuitable molding pour and foaming opening.

In other embodiments, the outer periphery of the filter media pack seal16 may vary with different inner surface shape molds. The embodimentillustrated in FIGS. 1-5 shows the spacer 36 as extendingperpendicularly between the outlet flow face 22 of the filter media pack12 and the molding platform 38. However, in other embodiments, thespacer 36 may extend in an oblique angle either angled toward or awayfrom the central axis 24. The filter media pack seal 16 in thisembodiment is formed independent of the annular seal 18 with the moldingplatform 38 as a barrier between them.

The uncured fluid sealing material for the filter media pack seal 16 maybe one of the materials described above for the annular seal material.The filter media pack seal 16 and the annular seal 18 may be moldedusing a same material or two different materials. In the embodimentdescribed above, the annular seal 18 and the filter media pack seal 16are molded in the same mold 32, with the annular seal 18 molded first.FIG. 15 shows the filter element 10 removed from such mold 32 after thefilter media pack seal 16 and the annular 18 are molded in the mold 32.In other embodiments, the filter media pack seal 16 and the annular seal18 may be molded in two different molds in two separate moldingprocesses.

FIGS. 6-8 illustrate a second embodiment of the present invention.Components of the filter element 110 of this embodiment are similar tothose described in the first embodiment, and includes the filter mediapack 12, the frame 66, and the annular seal 18. However, in thisembodiment, an annular sealing interface between the filter media pack12 and the frame 66 is formed by welding the filter media pack 12 to theframe 66 using a plastic welding process, rather than the filter mediapack seal 16 of the first embodiment. Plastic welding is, thus, used toattach and secure a frame to a fluted filter media pack and may alsoform an annular seal therebetween.

The frame 66 of this embodiment includes the seal support portion 68,which remains the same as described above for the first embodiment, andan annular plastic portion 70 for plastic welding the outer wraps of thefilter media pack 12. Therefore, in this embodiment, the frame 66 isformed at least in part from a plastic material suitable for a plasticwelding process. As shown in FIGS. 6-8, the annular plastic portion 70is formed around the outer periphery of the frame 66, and includes awelding portion 72 formed from a polymeric material suitable for aplastic welding process, and a safety portion 74. In other embodiments,a plastic welding portion of the frame 66 can be attached continuouslyaround the outer side of the filter media pack 12.

As shown in FIG. 6, the outer wraps of the filter media pack 12 areembedded in the welding portion 72 located around the inner diameter ofthe annular plastic portion 70, leaving a safety portion 74 to extendbeyond the outer periphery 13 of the filter media pack 12. As the filtermedia pack 12 is embedded into the welding portion 72, the safetyportion 74 remains and circumscribes the outer periphery 13 of thefilter media pack 12. An axial extension of the circumscribing safetyportion 74 beyond the outlet flow face 20 of the filter media pack 12equals the embedded length of the filter media pack 12. The outer wrapsof the filter media pack 12 embedded in the welding portion 72 of theframe 66 defines the annular sealing interface between the filter mediapack 12 and the frame 66.

All other components of the second embodiment remains the same as thosecomponents of the first embodiment as described above.

A method of making the filter element 110 of the second embodiment caninclude steps of forming the filter media pack 12, manufacturing theframe 66, molding the annular seal 18 on the seal support portion 68,and securing the filter media pack 12 against the frame 66. The processof forming the filter media pack 12 remains the same as described abovein the method of making the first embodiment. The process ofmanufacturing the frame 66 also remains largely the same, except theframe 66 in this embodiment includes the annular plastic portion 70thick enough to facilitate embedding instead of the molding receptacleregion 34 of the first embodiment. The frame 66 of the second embodimentis constructed at least in part from a plastic material, because theannular plastic portion 70 is formed from a plastic material suitablefor a plastic welding process, as discussed above.

The process of molding the annular seal 18 is the same as the processdescribed above in the method of making the first embodiment. However,the mold 76 in this embodiment may be constructed only for molding ofthe annular seal 18 without the peripheral wall 44 for separatelymolding the filter media pack seal 16. The mold 76 in the firstembodiment may also be utilized in this embodiment to mold the annularseal 18 around the seal support portion 68. The annular seal 18 in thisembodiment may be molded before or after securing the annular interfacebetween the filter media pack 12 and the frame 66.

The step of securing the filter media pack 12 and the frame 66, in thisembodiment, involves a plastic welding process to embed the outer wrapsof the filter media pack 12 in the annular plastic portion 70 of theframe 66. In one method of securing the interface between the filtermedia pack 12 and the frame 66, the annular plastic portion 70 is heateduntil the plastic material in the welding portion 72 becomes soft enoughto embed the outer wraps of the filter media pack 12. Then the filtermedia pack 12 is centered onto the frame 66 such that outer wraps of thefilter media pack 12 are on the heated welding portion 72. After thefilter media pack 12 is centered on the frame 66, a light pressure maybe applied evenly across the first flow face 20, causing the outer wrapsof the filter media pack to push axially into the heated welding portion72, without distorting or damaging the filter media pack 12.

The annular plastic portion 70 may be heated using any of theconventional plastic welding methods. For example, a hot air welder,also commonly referred to as a heat gun, may be used to heat the annularplastic portion 70. In such hot gas welding process, a heat gun is usedto apply a jet of hot air or gas to the annular plastic portion 70 untilthe plastic in the welding portion 72 becomes soft enough for theembedding process. Alternatively, the annular plastic portion 70 may beheated with high frequency electromagnetic waves, also known asinduction heating.

Ultrasonic welding or other similar friction welding processes may alsobe utilized. In an ultrasonic welding process, the filter media pack 12and the frame 66 are placed in an ultrasonic welding equipment whereinthey are exposed to a high-frequency, low-amplitude vibration between 15KHz to 40 KHz. The ultrasonic energy generated by the vibration heats acontact area between the filter media pack 12 and the annular plasticportion 70 and welds the filter media pack 12 to the welding portion 72of the frame 66.

FIGS. 9-11 illustrate a third embodiment of the invention. The thirdembodiment comprises the same constituents of the first embodiment, asdescribed above, with an exception of the frame 78. In this embodiment,the frame 78 includes the seal support portion 86 which remains the sameas before, and forms a molding receptacle region 80 defined by thespacer 79, a molding platform 82 and an outer wall 84.

As shown in FIGS. 9-11, the spacer 79 extends perpendicularly betweenthe outlet flow face 22 and the molding platform 82. However, in otherembodiments, the spacer may extend in an oblique angle relative to thecentral axis 24. The molding platform 82 extends radially beyond theouter periphery 13 of the filter media pack 12, and meets the outer wall84 extending axially upward. In this embodiment, the molding platform 82orthogonally meets the outer wall 84 with a rounded connecting point,yet in other embodiments, an angle between the molding platform 82 andthe outer wall 84 may be acute or obtuse with or without a roundedconnecting point.

The frame 78 in this embodiment is constructed such that the outer wall84 circumscribes the annular interface between the filter media pack 12and the frame 78, as well as a portion of the filter media pack outerperiphery 13 proximate the interface. The filter media pack seal 85 isformed in the molding receptacle region 80 and enclosed by the moldingreceptacle region 80.

The filter media pack 12 is secured against the frame 78 such that outermost wraps of the filter media pack 12 are in the molding receptacleregion 80 wherein the filter media pack seal 85 extends into openingsformed by some flutes along the outer wraps, preventing fluids frompassing through the outer wraps of the filter media pack. All othercomponents of this embodiment are the same as those components of thefirst embodiment as described above.

A method of making the filter element 120 of this embodiment may involvesteps of forming the filter media pack 12, manufacturing the frame 78,molding the annular seal 18 on the seal support portion 86, andseparately molding the filter media pack seal 85. Such method of makingthe filter element 120 is similar to the method of making the filterelement 10 of the first embodiment as described above. The process offorming the filter media pack 12 is the same as described above in thefirst embodiment. The process of manufacturing the frame 78 also remainsthe same, except that the frame 78 of this embodiment forms the moldingreceptacle region 80 which is configured differently than the moldingreceptacle region 34 of the first embodiment.

The process of molding the annular seal 18 is mostly the same as themolding process described above in the first embodiment. However, themold 88 in this embodiment may be constructed only for molding of theannular seal 18 without the raised peripheral wall 84, since the filtermedia pack seal 85 is molded in the molding receptacle region 80 of theframe 78, and not in the mold 88. The mold 32 in the first embodimentmay also be utilized in this embodiment just for molding the annularseal 18 around the seal support portion 86. In this embodiment, theannular seal 18 may be molded before or after molding of the filtermedia pack seal 85.

In a process of molding the filter media pack seal 85, an uncured fluidsealing material is poured into the molding receptacle region 80 formedby the frame 78. Then the filter media pack 12 is placed in the frame 78such that the outer wraps of the filter media pack 12 are in the moldingreceptacle region 80 and the outer periphery 13 of the filter media pack12 is spaced evenly relative to the circumscribing outer wall 84. Theouter wall 84 can include a set of locating ribs (not shown) to assistin centering the filter media pack 12 in the frame 78. In the moldingreceptacle region 80, the uncured fluid sealing material is allowed tofoam and extend into openings formed by some flutes along the outerwraps. The sealing material also foams up around the outer periphery 13of the filter media pack, sealing the interface between the filter mediapack 12 and the frame 78. Preferably, the minimum radial thickness ofthe filter media pack seal 85 (e.g. minimum distance between the outerside of the filter media pack 12 and an inner surface of the outer wall84) is typically between minimum 0.03 inches and 0.2 inches to allowsufficient room for a suitable molding pour and foaming opening. Theuncured fluid sealing material may include, but not limited to, variousfoaming polymers such as polyurethane. The sealing material for thefilter media pack seal 85 may be the same material used to form theannular seal 18, or may be formed from a different sealing material thanthe annular seal material.

FIGS. 12-14 illustrate a fourth embodiment of the invention. The filterelement of this embodiment includes the filter media pack 12, the filterframe 98 and the annular seal 18. The filter frame 98 includes a sealsupport portion 100, a seat 90, and an annular wall 92 having a chamfer104. The annular wall 92 extends axially along the outer periphery 13 ofthe filter media pack 12, circumscribing a portion of the outerperiphery 13. Alternatively, the annular wall 92 may be constructed in alonger length to completely circumscribe the outer periphery 13 of thefilter media pack 12, In one embodiment, the annular wall 92 may be 4inches in length, circumscribing only the corresponding outer peripheryof the filter media pack 12.

In this embodiment, the filter media pack 12 is attached to the frame 98with an adhesive. Conventionally, a ring of adhesive bead is appliedaround the outer surface of the filter media pack 12 before the filtermedia pack is inserted into the frame 98, because it is easier tocontrol application of the adhesive bead around the outer surface of thefilter media pack than an inner surface of the frame 98. However, it isdifficult to precisely center the filter media pack 12 into the frame98. Therefore, when the adhesive bead is applied around the outersurface of the filter media pack 12, the chamfer 104 of the frame 98often engages some parts of the adhesive ring prematurely causing a lossof a substantial amount of adhesive from those parts of the adhesivering, resulting in inadequate attachment and/or seal between the filtermedia pack 12 and the frame 98.

Therefore, in this embodiment, the adhesive bead 94 is applied around aninner surface of the annular wall 92 of the frame 98 in spaced relationfrom the seat 90. The adhesive bead 94 is applied such that the filtermedia pack 12 engages the adhesive bead 94 after being centered into theframe 98 guided by the chamfer 104. The amount and type of the adhesiveis judiciously selected to ensure that the filter media pack 12 issecurely attached to the frame 98 and the interface therebetween issealed. It is preferred that the adhesive bead 94 is applied between ¼inch to 1 inch above the seat 90 where a gap between the annular wall 92and the periphery of the filter media pack 13 is sufficiently less thana thickness of the adhesive bead 94 such that the filter media pack 12can adequately engage and shear the adhesive bead 94 as it travels downtoward the seat 90.

FIG. 12 shows the annular adhesive bead 94 as applied around the innersurface of the annular wall 92 at a preferred distance from the seat 90as described above. After the application of the adhesive bead 94, thefilter media pack 12 is inserted into the frame 98, guided by thechamfer 104. As shown in FIG. 13, the filter media pack 12 slides downalong the annular wall 92, toward the seat 90, and engages the adhesivebead 94. After the outer periphery 13 of the filter media pack 12engages the adhesive bead 94 and continues to slide downward, the outerperiphery 13 causes the adhesive bead 94 to shear along the annular wall92 toward the seat 90. When the filter media pack 12 finally reaches theseat 90, the adhesive bead is elongated, providing for a larger adhesionsurface to attach and seal the filter media pack 12 against the annularwall 92.

The change in surface area of the adhesive bead 94 is illustrated inFIGS. 12-14. In FIG. 12, the adhesive bead 92 is shown as applied in theinner surface of the annular wall 92. FIG. 13 illustrates the adhesivebead 94, as the outer periphery 13 of the filter media pack 12, isengaged. Finally, elongated surface area of the adhesive bead 94 fromthe shearing action is shown in FIG. 14. Also, as shown in FIG. 14, theadhesive 94 seals the interface between the filter media pack 12 and theframe 98, preventing fluids from passing between the filter media pack12 and the annular wall 92.

FIGS. 16-19 illustrate a fifth embodiment of the invention. The fifthembodiment is similar to the first embodiment, except the filter mediapack seal 16 and the annular seal 18 are more distinctively separatedsince they are molded in a mold 32 including a mold undercut 162. Thatis, the mold undercut 162 reduces a risk of an uncured fluid materialfor the filter media pack seal 16 and/or the annular seal 18 fromseeping between the chamfered seating surface 40 and the tapered region50 of the mold 32, thereby preventing a filter media pack seal materialfrom mixing with an annular seal material. In this embodiment, formingof the filter media pack seal 16 and forming of the annular seal 18 arecontained in their respective mold cavities, thus the filter media packseal 16 and the annular seal 18 are distinctively separate from eachother.

This embodiment is particularly advantageous wherein the filter mediapack seal 16 and the annular seal 18 are formed of two different typesof polymers. Preferably, the filter media pack seal 16 of thisembodiment is formed of a rigid urethane while the annular seal 18 isformed of a softer, urethane foam. A rigid urethane can be moreadvantageous than a softer urethane foam when used to form the filtermedia pack seal 16, since it can provide structural support and betterprotect the outer edges of the outlet flow face 22. On the other hand,the softer urethane foam, which is more resilient than the rigidurethane, may be better suited for the annular seal 18 for providingsealing function between the filter element 10 and the filter housing.

In such an embodiment, the filter media pack seal 16 may be formed of arigid urethane having a durometer reading greater than 60A (alldurometer readings herein are in ASTM D2240 type A scale using ShoreDurometer Type A testing equipment), and preferably between 90A and 95A;while the annular seal 18 for the housing has a durometer reading lessthan 25A, and preferably between 5A and 8A. The rigid urethane used forthe filter media pack seal 16 is a urethane material that expands lessthan 40% in volume during curing, and the softer urethane foam used forthe annular seal 18 is a urethane material that expands more than 40% ofvolume during curing. Typically, the rigid urethane and the softerurethane foam materials are formulated differently, each including adifferent polyol. In this manner, the filter media pack seal 16 ismolded with a much more controlled process while the annular seal 18 isless controlled, but more resilient and forgiving for its use with anexternal housing surface. Additionally, the filter media pack seal 16 isa protective border frame at the outlet end to protect against bumpsduring insertion and otherwise. In one embodiment, the filter media packseal 16 has a durometer reading of about 92A which is formed of a rigidurethane that foams about 25% in volume during curing, and the annularseal 18 has a durometer reading of about 7A and is formed of a softerurethane that foams about 60% in volume during curing.

In other embodiments, the media pack seal 16 which also is a framestructure can also support the seal for housing. In such embodiments, aframe structure may be molded to the filter media pack 12 similar to theborder frame 150 as described above. (FIGS. 20-22). Such a framestructure may have a media pack seal portion and annular seal supportportion integrally formed in a mold. As it was with the border frame150, this frame structure is integrally bonded when some of an uncuredframe material enters some flutes and circumscribes the periphery offilter media pack 12 and cures. Once cured, the frame structure isintegrally secured to the filter media pack 12 and an annular seal canthen be molded on the annular seal support portion of the framestructure in a separate molding process.

The embodiment depicted in FIGS. 16-19 is shown with a protectivewrapper 200. The protective wrapper 200 can protect the outer face sheet13 of the filter media pack 12 from being damaged or punctured duringhandling. The protective wrapper 200 may also enhance overall appearanceof the filter element 10 by hiding any imperfections such as makings,glue spots, etc. on the outer periphery of the filter medial pack 12from manufacturing process. The protective wrapper may be formed of anysuitable materials including, but not limited to, a spunboundedpolymeric material manufacture by Reemay®, a plastic, an impermeablematerial such as a metalized plastic film, and a chipboard such as aheavy duty construction paper.

As it was with the first embodiment, the filter media pack seal 16 andthe annular seal 18 are molded in a mold 32. However, the mold 32 ofthis embodiment includes a mold undercut 162 to ensure that a polymericmaterial for the filter media pack seal 16 does not mix with a polymericmaterial for the annular seal 18. The tapered region 50 of the mold 32in this embodiment is connected to the undercut 162. As shown in FIG.16, a portion of the molding platform 38 of this embodiment sits on themold undercut 162. As a result, an uncured fluid sealing material forthe annular seal 18 foams and rises around the seal support portion 26and is capped by the mold undercut 162 and the molding platform 38. Allother components and aspects of this embodiment remains the same as thefirst embodiment.

The embodiments described herein have the frame 14, 66, 78, 98 securedagainst the flow face 22 of the filter media pack 12. The flow face 22may be an upstream end of the filter element in some embodiments, andmay be a downstream end in other embodiments. The flow face without theframe 14, 66, 78, 98 can be protected by the border frame 19, 150 asshown in FIGS. 1,2 and 19, or left unsupported in some embodiments. Theborder frame 19, 150 may be added to any embodiments of the presentinvention and may be formed from the same material used to form thefilter media pack seal 16 or the annular seal 18, or may be formed froma different suitable material. In some embodiments, the border frame 19,150 may provide an additional sealing surface between the filter element10 and the filter housing.

FIGS. 23-24 illustrate a filter element 300 according to a sixthembodiment of the invention. The sixth embodiment is similar to thefifth embodiment, except a space 302 of this embodiment is radiusedinstead of the straight spacer 36, as shown in FIGS. 16-19. Further, themold 304 may be configured to have a smaller annular space 306 betweenthe outer periphery 308 of the filter media pack 310 and the mold innerwall 312 than the annular space 62 of the fifth embodiment. Further, themold 304, as shown, does not include a plurality of locating ribs.

In this embodiment, the filter media pack 310 is generally centered intothe mold 32, partially guided by a slanted surface 314, which is locatednear the top of the mold 304. The slanted surface 314 provides a wideropening toward the top of the mold 304 and reduces the size of the moldopening as it slops toward the center of the mold 304. As such, someportions of the filter media pack 310 may come in contact with theslanted surface 314 and slide down, as it is inserted into the mold 304.Depending upon the actual perimeter of the media pack (recognizingtolerance variations due to manufacture of different media packs, andthat the outer wrap ends typically on one side creating a discontinuitywith the terminating edge), portions of the media pack may also contactor about contact the inner wall 312 of the mold. Thus, the mold wallsare arranged for available contact with the outer periphery of thefilter media pack, because the frame does not intervene therebetweenduring insertion into the mold. Further, the relatively small annularspace 306 can reduce a variance of the annular space 306 around the mold304, thus the filter media pack 310 may be generally centered into themold 304 without the plurality of locating ribs. Thus, this embodimenttoo works by locating the filter media pack by direct contact whennecessary so as to correct misalignment when the media pack is plungedinto the mold and/or to otherwise center the media pack.

As it was with the fifth embodiment, a filter media pack seal 316 may beformed of a rigid urethane foam material and an annular seal 318 may beformed of a softer urethane foam material. Similar to the moldingmethods described at length with regard to the first embodiment and thefifth embodiment, the annular seal 318 is first molded. Then an uncuredrigid urethane material for the filter media pack seal 316 is poured,wherein the filter media pack 310 is generally centered. As shown inFIG. 23, the filter media pack 310 is placed approximate the vertex ofthe radiused spacer 302. The radiused spacer 302 may act as an undercutduring a curing process, wherein the uncured rigid urethane materialfoams and rises. During the curing process, some of the uncured rigidurethane material enters openings formed by flutes in a moldingreceptacle region 320, defined by the radiused spacer 302, a moldingplatform 322 and the mold inner wall 312. Further, some of the uncuredrigid urethane material rises around the periphery 308 of the filtermedia pack 310, and cures in the annular space 306. When cured, thefilter media pack seal 316 is formed, securely attaching the filtermedia pack 310 and the frame 324.

All references, including publications, patent applications, and patentscited herein are hereby incorporated by reference to the same extent asif each reference were individually and specifically indicated to beincorporated by reference and were set forth in its entirety herein.

The use of the terms “a” and “an” and “the” and similar referents in thecontext of describing the invention (especially in the context of thefollowing claims) is to be construed to cover both the singular and theplural, unless otherwise indicated herein or clearly contradicted bycontext. The terms “comprising,” “having,” “including,” and “containing”are to be construed as open-ended terms (i.e., meaning “including, butnot limited to,”) unless otherwise noted. Recitation of ranges of valuesherein are merely intended to serve as a shorthand method of referringindividually to each separate value falling within the range, unlessotherwise indicated herein, and each separate value is incorporated intothe specification as if it were individually recited herein. All methodsdescribed herein can be performed in any suitable order unless otherwiseindicated herein or otherwise clearly contradicted by context. The useof any and all examples, or exemplary language (e.g., “such as”)provided herein, is intended merely to better illuminate the inventionand does not pose a limitation on the scope of the invention unlessotherwise claimed. No language in the specification should be construedas indicating any non-claimed element as essential to the practice ofthe invention.

Preferred embodiments of this invention are described herein, includingthe best mode known to the inventors for carrying out the invention.Variations of those preferred embodiments may become apparent to thoseof ordinary skill in the art upon reading the foregoing description. Theinventors expect skilled artisans to employ such variations asappropriate, and the inventors intend for the invention to be practicedotherwise than as specifically described herein. Accordingly, thisinvention includes all modifications and equivalents of the subjectmatter recited in the claims appended hereto as permitted by applicablelaw. Moreover, any combination of the above-described elements in allpossible variations thereof is encompassed by the invention unlessotherwise indicated herein or otherwise clearly contradicted by context.

1. A filter element comprising: a filter media pack having a centralaxis passing through opposed flow faces, a frame secured to the filtermedia pack, the frame having a seal support portion and forming at leasta portion of a molding receptacle region; an annular seal carried by theseal support portion; and a filter media pack seal molded independent ofthe annular seal generally occupying the molding receptacle region andsealing an annular interface between the filter media pack and theframe; the filter media pack seal being molded of foam material anddefining an exposed free rise surface extending outwardly from thefilter media pack; and wherein the filter media pack seal defines anexposed outermost annular surface not surrounded by the frame.
 2. Thefilter element of claim 1, wherein the frame further includes a spacerand a molding platform defining at least a portion of the moldingreceptacle region, the molding platform including a terminal free edgewhich has a chamfered seating surface, and the molding platformextending radially outward relative to an outer periphery of the filtermedia pack and containing a bottom edge of the filter media pack seal.3. The filter element of claim 1, wherein the filter media pack sealincludes a tapered region extending into a larger periphery, sealing theannular interface between the filter media pack and the frame, andfurther circumscribing a portion of the filter media pack proximate theannular interface.
 4. The filter element of claim 1, wherein the filtermedia pack is a fluted filter media comprising a plurality of flutes,first selected ones of the plurality of flutes closed proximate thefirst flow face and second selected ones of the plurality of flutesclosed proximate the second flow face, and the fluted filter media packincluding outer wraps.
 5. The filter element of claim 1, wherein thefilter media pack seal comprises an urethane foam material.
 6. Thefilter element of claim 1, wherein the annular seal comprises anurethane foam material, and the annular seal molded to the seal supportportion.
 7. The filter element of claim 1, wherein the frame furtherincludes a spacer, a molding platform and an outer wall defining themolding receptacle region; the molding receptacle region containing thefilter media pack seal.
 8. The filter element of claim 7, wherein thefilter media pack is a fluted filter media comprising a plurality offlutes, first selected ones of the plurality of flutes closed proximatethe first flow face and second selected ones of the plurality of flutesclosed proximate the second flow face, and the fluted filter media packincluding outer wraps.
 9. The filter element of claim 7, wherein thefilter media pack seal comprises an urethane foam material; the annularseal comprises an urethane foam material; and the annular seal is moldedto the seal support portion.
 10. The filter element of claim 1, whereinthe filter media seal and the annular seal are separated by a moldingplatform of the frame and do not overlap.
 11. The filter element ofclaim 10, wherein the filter media seal comprises a rigid urethane andthe annular seal comprises a urethane foam material which is softer thanthe rigid urethane.
 12. The filter element of claim 1 wherein the foammaterial is urethane.
 13. The filter element of claim 1, wherein thefree rise surface extends at a minimum at least 0.03 inches from thefilter media pack to provide means for allowing sufficient room for amolding pour and foaming opening.
 14. A filter element comprising: afilter media pack having a central axis passing through opposed flowfaces, a frame secured to the filter media pack, the frame having a sealsupport portion and forming at least a portion of a molding receptacleregion; an annular seal carried by the seal support portion; and afilter media pack seal molded independent of the annular seal generallyoccupying the molding receptacle region and sealing an annular interfacebetween the filter media pack and the frame, wherein the filter mediapack is a fluted filter media comprising a plurality of flutes, firstselected ones of the plurality of flutes closed proximate the first flowface and second selected ones of the plurality of flutes closedproximate the second flow face, and the fluted filter media packincluding outer wraps, wherein the frame includes a spacer and a moldingplatform defining at least a portion of the molding receptacle region,the spacer extending between one of the flow faces and the moldingplatform, the spacer allowing a filter media pack seal material to flowinto openings formed by some flutes along the outer wraps of the filtermedia pack, thereby sealing the outer wraps of the filter media pack.15. A filter element comprising: a filter media pack having a centralaxis passing through opposed flow faces, a frame secured to the filtermedia pack, the frame having a seal support portion and forming at leasta portion of a molding receptacle region; an annular seal carried by theseal support portion; and a filter media pack seal molded independent ofthe annular seal generally occupying the molding receptacle region andsealing an annular interface between the filter media pack and theframe, wherein the frame further includes a spacer, a molding platformand an outer wall defining the molding receptacle region; the moldingreceptacle region containing the filter media pack seal, wherein thespacer extends between one of the flow faces and the molding platform,the molding platform extends radially beyond an outer periphery of thefilter media pack, the outer wall extends axially from the moldingplatform towards the filter media pack, and the molding platform and theouter wall are adapted for circumscribing a portion of the filter mediapack proximate the annular interface.
 16. A filter element comprising: afilter media pack having a central axis passing through opposed flowfaces, a frame secured to the filter media pack, the frame having a sealsupport portion and forming at least a portion of a molding receptacleregion; an annular seal carried by the seal support portion; and afilter media pack seal molded independent of the annular seal generallyoccupying the molding receptacle region and sealing an annular interfacebetween the filter media pack and the frame, wherein the filter mediapack is a fluted filter media comprising a plurality of flutes, firstselected ones of the plurality of flutes closed proximate the firstflow, face and second selected ones of the plurality of flutes closedproximate the second flow face, and the fluted filter media packincluding outer wraps, wherein the spacer allows a filter media packseal material to flow into openings formed by some flutes along theouter wraps of the filter media pack, thereby sealing the outer wraps ofthe filter media pack.